Title: Stable ferrous-ferric nitrate solutions for fischer-tropsch catalyst preparation.Abstract: A method of producing stable ferrous nitrate solution by dissolving iron in nitric acid to form a ferrous nitrate solution and maintaining the solution at a first temperature for a first time period, whereby the Fe(II) content of the ferrous nitrate solution changes by less than about 2% over a second time period. A method of producing stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate and having a desired ratio of ferrous iron to ferric iron, including obtaining a stable ferrous nitrate solution; dissolving iron in nitric acid to form a ferric nitrate solution; maintaining the ferric nitrate solution at a second temperature for a third time period; and combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution. A method of preparing an iron catalyst is also described. ...

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 61/058,104 filed Jun. 2, 2008, the disclosure of which is hereby incorporated herein by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to iron Fischer-Tropsch catalysts. More particularly, the present invention relates to a method for preparing stable Fe(II)/Fe(III) nitrate and/or ferrous nitrate solutions to produce Fischer-Tropsch synthesis catalyst, and the catalyst produced thereby. Still more specifically, the present invention relates to a method of producing a Fischer-Tropsch catalyst by precipitating iron from an acid solution comprising a desired ratio of ferrous iron to ferric iron and wherein the acid solution is stable for a desired time period.

2. Background of the Invention

The Fischer-Tropsch (FT) technology is used to convert a mixture of hydrogen and carbon monoxide (synthesis gas or syngas) to valuable hydrocarbon products. Often, the process utilizes a slurry bubble column reactor (SBCR). The technology of converting synthesis gas originating from natural gas into valuable primarily liquid hydrocarbon products is referred to as Gas-To-Liquids (GTL) technology. When coal is the raw material for the syngas, the technology is commonly referred to as Coal-To-Liquids (CTL). The FT technology is one of several conversion techniques included in the broader GTL/CTL technology.

One of the primary difficulties encountered in using iron-based catalysts for carrying out the FT reaction in a slurry bubble column reactor (SBCR) is the breakdown of the initial catalyst particles into very small particles, i.e. less than 5 microns in size. Although the small particle size is advantageous for increasing surface area and reaction rate of the catalyst, the problem lies in separating the small catalyst particles from the wax slurry medium. Separating the catalyst particles from the wax is desired since the iron catalyst when operated under the most profitable conditions wherein wax is produced utilizes removal of the wax from the reactor to maintain a constant height of slurry in the reactor.

It is impossible to determine the actual attrition resistance that is sufficient without knowing the type of reactor system, the type of wax/catalyst separation system and the system operating conditions.

Heretofore, attempts at developing strengthened iron-based catalysts have focused on producing the strongest possible catalysts, regardless of the actual strength sufficient for a particular system. Such approaches sacrifice activity and selectivity for catalyst strength which may exceed that which is sufficient. Most of the prior art has focused on attempting to maximize strength of the catalyst without due regard for the negative impact of high levels of strengthener, e.g. silica, on activity and selectivity. Further, tests for catalyst strength have been carried out ex-situ, i.e. outside the SBCRs. Many of the tests have been conducted in a stirred tank reactor (autoclave) which subjects the catalyst to severe shearing forces not typically encountered in slurry bubble column reactors.

Improved catalyst strength can be achieved by depositing the iron on a refractory support such as silica, alumina or magnesia or by adding a structural promoter to the baseline catalyst. The challenge is to strengthen the catalyst without appreciably compromising the activity and selectivity of the catalyst.

Formation of strengthened FT iron catalysts which utilizes a desired ratio of ferric to ferrous iron in an acid solution from which precipitation of iron phase occurs has been reported in U.S. patent application Ser. No. 12/198,459 filed Aug. 26, 2008 and entitled, “Strengthened Iron Catalyst for Slurry Reactors.” The disclosure of U.S. patent application Ser. No. 12/198,459 is incorporated hereby herein for all purposes not inconsistent with this disclosure. Ferrous nitrate solution is reported to be very unstable in the literature. Production of stable ferrous nitrate solutions and stable solutions comprising a desired ratio of ferrous to ferric iron is challenging, and the production thereof will lead to more consistent iron-catalyst formation and a decrease in the time and costs of catalyst formation.

Accordingly, there is a need for a method of producing stable ferrous nitrate solutions and stable nitrate solutions comprising a desired ratio of ferric to ferrous iron. Also needed is a method of producing an iron FT catalyst which incorporates the use of the stable iron nitrate solutions. Use of these methods should desirably allow production of an iron FT catalyst which has resistance against breakdown during FT reaction and also maintains high activity and selectivity toward high molecular weight hydrocarbons. A method for stabilization of Fe(II)/Fe(III) nitrate solution should enhance the rate of the catalyst manufacturing process at dissolution and/or precipitation steps, desirably increase reproducibility of catalyst manufacture.

SUMMARY

Herein disclosed is a method for producing a stable ferrous nitrate solution, the method comprising dissolving iron in nitric acid having a first nitric acid concentration to form a ferrous nitrate solution and maintaining the solution at a first temperature for a first time period, whereby the Fe(II) content of the ferrous nitrate solution changes by less than about 2 weight percent over a second time period. In embodiments, the first nitric acid concentration is in the range of from about 5 to about 10 weight percent. In embodiments, the first nitric acid concentration is about 6 weight percent. In embodiments, the first temperature is a temperature in the range of from about 25° C. to about 35° C. In embodiments, the first time period is greater than 30 minutes. In embodiments, the first time period is greater than 45 minutes. In embodiments, the method further comprises covering the ferrous nitrate solution during the first time period. In embodiments, the second time period is at least one hour. In embodiments, the second time period is at least one day. In embodiments, the second time period is at least two days. The method can further comprise filtering the stable ferrous nitrate solution. Also disclosed is a stable ferrous nitrate solution produced via the disclosed method.

Also disclosed is a method of producing a stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate and having a desired ratio of ferrous iron to ferric iron, the method comprising: obtaining a stable ferrous nitrate solution by the method disclosed above; dissolving iron in nitric acid having a second nitric acid concentration to form a ferric nitrate solution, wherein the second nitric acid concentration is greater than the first nitric acid concentration; maintaining the ferric nitrate solution at a second temperature for a third time period; and combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution having the desired ratio of ferrous iron to ferric iron, wherein the Fe(II) content of the stable Fe(II)/Fe(III) nitrate solution changes by less than about 2 weight percent over a fourth time period. In embodiments, the second nitric acid concentration provides a specific gravity of the ferric nitrate solution of greater than 1.115. In embodiments, the method further comprises heating the ferric nitrate solution to a third temperature for a fifth period of time. The third temperature can be greater than the first temperature. In embodiments, the third temperature is a temperature of greater than about 70° C. In embodiments, the fifth time period is a time greater than about 40 minutes. In embodiments, the first nitric acid concentration is in the range of from about 5 to about 10 weight percent. In embodiments, the first nitric acid concentration is about 6 weight percent. In embodiments, the first temperature is a temperature in the range of from about 25° C. to about 35° C. In embodiments, the first time period is greater than 30 minutes. In embodiments, the first time period is greater than 45 minutes. In embodiments, the method further comprises covering the ferrous nitrate solution during the first time period. In embodiments, the second time period is at least one hour. In embodiments, the second time period is at least one day. In embodiments, the second time period is at least two days. The method can further comprise covering the ferric nitrate solution during the third time period. In embodiments, the fourth time period is at least one hour. In embodiments, the fourth time period is at least one day. In embodiments, the desired ratio of ferrous iron to ferric iron is about 1:3. The method can further comprise allowing the stable ferrous nitrate solution to cool to room temperature prior to combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution. The method can further comprise filtering the ferrous nitrate solution, the ferric nitrate solution, or both. Also disclosed is a stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate formed according to the previously-described method.

Also disclosed is a method of producing an iron catalyst, the method comprising: obtaining a stable Fe(II)/Fe(III) nitrate solution according to the above procedure; and combining the stable Fe(II)/Fe(III) nitrate solution with a precipitating agent whereby catalyst precipitate is formed. In embodiments, the stable Fe(II)/Fe(III) nitrate solution has a desired ratio of ferrous iron to ferric iron of about 1:3. In embodiments, the precipitating agent is selected from the group consisting of NH4OH, (NH4)2CO3, NH4HCO3, NaOH, Na2CO3, NaHCO3, KOH, K2CO3, KHCO3, and combinations thereof. The method can further comprise co-precipitating at least one other metal or metalloid from a nitrate solution. The at least one other metal or metalloid can be selected from the group consisting of magnesium, copper, aluminum, silicon, and combinations thereof. In embodiments, the method further comprises washing the precipitate. In embodiments, the method further comprises alkalizing the precipitate with an alkaline material. The alkaline material can comprise potassium carbonate. In embodiments, the method further comprises promoting the precipitate by contacting the precipitate with a structural promoter. The structural promoter can comprise liquid potassium silicate. In embodiments, the structural promoter comprises tetraethyl ortho silicate, TEOS. Also disclosed is an iron catalyst formed by the previously-described method.

The present invention comprises a combination of features and advantages which enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is a plot of pH of ferrous nitrate solution as a function of time.

FIG. 2 is a plot of pH of ferric nitrate solution as a function of time.

FIG. 3 is a plot of pH as a function of time for a solution containing 25% ferrous/75% ferric nitrate (cold).

FIG. 4 is a plot of pH as a function of time for a solution containing 25% ferrous/75% ferric nitrate (hot).

NOTATION AND NOMENCLATURE

The term “Fe(II)/Fe(III) nitrate solution” is used herein to refer to an iron nitrate solution comprising ferrous nitrate and ferric nitrate.

Unless otherwise stated, percent or % is used to refer to weight percentages.

DETAILED DESCRIPTION

I. Overview

In an FT process, a hydrogen and carbon monoxide-containing gas stream is introduced into a Fischer-Tropsch reactor which can employ a catalyst slurry using an iron-based catalyst; the catalyst slurry can comprise a precipitated iron catalyst; the precipitated iron catalyst can be promoted with predetermined amounts of potassium and copper depending on the pre-selected probability of linear condensation polymerization and the product molecular weight distribution sought.

Production of the iron FT catalyst can comprise addition of an acid solution to a base, addition of a base solution to an acid solution, or a combination thereof. The acid solution can comprise a certain ratio of ferric to ferrous iron. This disclosure provides a means for obtaining a desired ratio of ferric to ferrous iron in the acid solution, whereby the acid solution is stable for a time and maintains the desired ratio of ferric to ferrous iron.

According to literature, when iron is dissolved in nitric acid of specific gravity of 1.05, ferrous nitrate is produced, but with more concentrated acids, a mixture of ferrous and ferric nitrates is produced. With nitric acid of specific gravity of 1.115, substantially only ferric nitrate is produced.

Iron is combined with nitric acid to produce ferrous nitrate, Fe(NO3)2 according to the following equations:

Fe+2HNO3→Fe(NO3)2+H2. (1)

4Fe+10HNO3→4Fe(NO3)2+NH4NO3+3H2O. (1b)

Ferrous nitrate is known to be very unstable and yellow oxides (Fe2O3) may be precipitated on exposure to air according to the following equation:

6Fe(NO3)2+5H2O→3Fe2O3+2NO+10HNO3. (2)

Ferrous oxidation and precipitation leads to the production of ferric hydroxide (Fe(OH)3) according to the following equation:

3Fe(NO3)2+7H2O→3Fe(OH)3+5HNO3+NO. (3)

With time, ferric hydroxide may be mineralized, and ferric iron oxide formed.

Ferrous iron normally can be oxidized to ferric iron in minutes, however, the time for this oxidation is dependent on pH, temperatures and the presence of other soluble ions. The lower the pH and temperature, the longer time taken for the completion of the oxidation reaction. At pH of 7.0, oxidation of Fe(II) can take 1 hour at 21° C. and 10 hours at 5° C. At pH of 6, it can take 100 hours.

With nitric acid of specific gravity at around 1.115, substantially only ferric nitrate, Fe(NO3)3, is produced, and ferric (Fe(III)) nitrate is known to be quite stable. Ferric nitrate is produced by the following reactions:

Fe+3HNO3→Fe(NO3)3+1.5H2, and (4)

2Fe+8HNO3→2Fe(NO3)3+2NO+4H2O. (4b)

Herein disclosed is a ferrous nitrate solution which is stable for a desired time period of at least one hour, at least two hours, at least one day, or at least two days. Also disclosed herein is a stable Fe(II)/Fe(III) nitrate solution formed by mixing of stable ferrous nitrate solution of this disclosure with ferric nitrate solution. In embodiments, the ferrous nitrate solution and/or the Fe(II)/Fe(III) nitrate solution is stable for a period of at least one hour, at least two hours or at least one day. In embodiments, the ferrous nitrate solution and/or the Fe(II)/Fe(III) nitrate solution is stable for a period of at least two days. The stability of the solutions can be determined by the amount of Fe(II) in the solutions (ferrous nitrate solution or ferric/ferrous nitrate solution comprising both ferrous nitrate and ferric nitrate). A “stable” solution is defined herein as a solution that has a percent Fe(II) that changes by less than a desired amount (e.g. by less than about 2% or less than about 1%) over a desired time period, e.g. at least one hour, at least two hours, at least one day, at least two days, or some time therebetween. In embodiments, a stable solution has a percent Fe(II) that changes by less than 2 weight percent over a desired time period. In embodiments, a stable solution has a percent Fe(II) that changes by less than 2 weight percent over a time period of at least one day. In embodiments, a stable solution has a percent Fe(II) that changes by less than 1 weight percent over a desired time period. In embodiments, a stable solution has a percent Fe(II) that changes by less than 1 weight percent over a time period of at least one day.

To achieve a targeted Fe(II)/Fe(III) nitrate ratio, the precipitation step of iron catalyst manufacturing can be very difficult if the Fe(II)/Fe(III) nitrate solution is not stable. In unstable solutions, the Fe(II)/Fe(III) nitrate ratio may keep changing after mixing the Fe(II) and Fe(III) solutions. This can impede the subsequent precipitation process. The method herein disclosed allows stabilization of an Fe(II)/Fe(III) solution and helps maintain a targeted Fe(II)/Fe(III) ratio. This enables effective production of a consistent catalyst, sometimes in a shortened production time. Implementation of the disclosed method may provide a significant cost savings in terms of catalyst quality, material, time and/or labor in the catalyst manufacturing process.

Ferrous nitrate solution will be referred to at times as ferrous nitrate solution (1); ferric nitrate solution will be referred to at times as ferric nitrate solution (2); ferric/ferrous nitrate solution comprising ferrous nitrate and ferric nitrate will be referred to at times as ferric/ferrous nitrate solution (3).

Many factors affect the Fe(II) stability in mixed Fe(II)/Fe(III) solutions. To increase stability of Fe(II)/Fe(III) mixtures, in embodiments, the mixtures are covered in order to prevent volume loss over time. To enhance reproducibility, in embodiments, acid addition is performed at a temperature of greater than about 30° C. After the acid addition step is complete, the solution can be stirred for a time, e.g. at least 45 minutes, prior to heating. This may ensure more complete dissociation of the iron metal. In embodiments, solutions that are filtered after the addition of acid are stable for at least one hour. If undissociated iron is left in the ferrous nitrate and ferric nitrate solutions, the Fe(II) content in the mixed solution (3) may be stable for a longer period of time than if the individual ferrous nitrate solution (1) and ferric nitrate solution (2) are filtered. Without wishing to be limited by theory, this may be because the amount of Fe(II) that oxidizes to Fe(III) over time is of the same magnitude as the remaining elemental iron that is oxidized to Fe(II) in the acid solution.

According to this disclosure, formation of a stable ferrous nitrate solution comprises dissolving iron in nitric acid having a first nitric acid weight percent, and maintaining the solution at a first temperature for a first period of time. The ferrous nitrate solution can be stirred during the first period of time. In embodiments, the first temperature is a temperature in the range of from about 25° C. to about 35° C. In embodiments, the first temperature is a temperature in the range of from about 30° C. to about 35° C. In embodiments, the first period of time is greater than about 30 minutes. In embodiments, the first period of time is greater than about 40 minutes. In embodiments, the first period of time is greater than about 45 minutes. In embodiments, the nitric acid used to dissolve the iron for preparation of the stable ferrous nitrate solution has a first nitric acid weight percent of about 5-10 weight percent, 6-9 weight percent, or about 6 weight percent.

In embodiments, stable ferrous nitrate solution is stable for a second time period. In embodiments, the second time period is at least one hour, at least two hours, at least one day, or at least two days. In embodiments, stable ferrous nitrate solution is stable for at least one day. In embodiments, stable ferrous nitrate solution is stable for at least two days. In embodiments, stable ferrous nitrate solution is stable for at least three days. In embodiments, the percent Fe(II) in the stable ferrous nitrate solution changes by less than about 1% over a period of about one hour, at least two hours, at least one day, or at least two days. In embodiments, the percent Fe(II) in the stable ferrous nitrate solution changes by less than about 2% over a period of about one hour, about two hours, or about one day. In embodiments, the percent Fe(II) in the stable ferrous nitrate solution changes by less than about 2% over a period of about two days. In embodiments, the ferrous nitrate solution is filtered. In embodiments, the stable ferrous nitrate solution is covered during the first time period.

Formation of ferric acid solution comprises dissolving iron in nitric acid having a second weight percent nitric acid and maintaining the solution at a second temperature for a third period of time. In embodiments, the second temperature is a temperature in the range of from about 60° C. to about 80° C. In embodiments, the second temperature is a temperature in the range of from about 60° C. to about 70° C. In embodiments, the second temperature is a temperature of about 65° C. In embodiments, the second temperature is a temperature of greater than about 70° C. In embodiments, the third period of time is a time of greater than about 30 minutes. In embodiments, the third period of time is a time of greater than about 40 minutes. In embodiments, the third period of time is a time of greater than about 45 minutes. In embodiments, the nitric acid used for dissolution of iron in preparation of ferric nitrate solution has a weight percentage of nitric acid in the range of from about 10-20 weight percent. In embodiments, the nitric acid used for dissolution of iron in preparation of ferric nitrate solution has a weight percentage of nitric acid in the range of from about 12-18 weight percent. In embodiments, the nitric acid used for dissolution of iron in preparation of ferric nitrate solution has a weight percentage of nitric acid of about 13 weight percent. In embodiments, the nitric acid is about 17 weight percent nitric acid. In embodiments, the ferric nitrate solution is filtered. In embodiments, the ferric nitrate solution is covered during the third time period.

In embodiments, forming a solution of ferric nitrate further comprises heating the ferric nitrate solution to a temperature of greater than about 70° C. In embodiments, forming a solution of ferric nitrate further comprises heating the ferric nitrate solution to a temperature of greater than about 75° C. In embodiments, forming a solution of ferric nitrate further comprises heating the ferric nitrate solution to a temperature in the range of from 35° C. to 75° C.

In embodiments, combining stable ferrous nitrate solution and ferric nitrate solution such that a stable Fe(II)/Fe(III) nitrate solution is formed having a desired ratio of ferrous to ferric iron comprises combining stable ferrous nitrate solution and ferric nitrate solution to produce a ferric/ferrous nitrate solution comprising about 20-30 weight percent ferrous iron and about 70-80 weight percent ferric iron. In embodiments, combining stable ferrous nitrate solution and ferric nitrate solution such that a stable Fe(II)/Fe(III) nitrate solution is formed having a desired ratio of ferrous to ferric iron comprises combining stable ferrous nitrate solution and ferric nitrate solution to produce a ferric/ferrous nitrate solution comprising about 22-28 weight percent ferrous iron and about 72-78 weight percent ferric iron. In embodiments, combining stable ferrous nitrate solution and ferric nitrate solution such that a stable Fe(II)/Fe(III) nitrate solution is formed having a desired ratio of ferrous to ferric iron comprises combining stable ferrous nitrate solution and ferric nitrate solution to produce a ferric/ferrous nitrate solution comprising about 25 weight % ferrous iron and about 75 weight percent ferric iron. In embodiments, the percent Fe(II) in the stable Fe(II)/Fe(III) nitrate solution changes by less than about 1 weight percent over a period of about one hour, about two hours, or about one day. In embodiments, the percent Fe(II) in the stable Fe(II)/Fe(III) nitrate solution changes by less than about 2 weight percent over a period of about one hour, about two hours, or about one day. In embodiments, the percent Fe(II) in the stable Fe(II)/Fe(III) nitrate solution changes by less than about 2% over a period of about two days. In embodiments, the ferrous nitrate solution, the ferric nitrate solution, or both are filtered prior to combining to produce the Fe(II)/Fe(III) nitrate solution.

In embodiments, a mixture of ferrous nitrate solution and ferric nitrate solution according to this disclosure is utilized to make iron-based Fischer-Tropsch catalyst. In embodiments, the desired ferrous nitrate/ferric nitrate solution comprises 20-30 weight percent (e.g. 25 weight percent) ferrous nitrate and about 70-80 weight percent (e.g. about 75 weight percent) ferric nitrate. Although the examples presented herein provide specific ratios of ferric/ferrous nitrate, the disclosed method of stabilizing ferrous nitrate solutions and ferric/ferrous nitrate solutions produced therefrom, can be used to stabilize Fe(II)/Fe(III) nitrate solutions having any desired ratio of ferric to ferrous nitrate.

Although discussed with respect to the production of iron FT catalyst, the stabilized ferrous nitrate solution and/or the stabilized ferric/ferrous nitrate solution herein disclosed may be used for purposes other than production of FT catalyst, and discussion thereof is not meant to be limiting.

In embodiments, an iron FT catalyst is formed substantially according to the description in U.S. Pat. No. 5,504,118 and/or U.S. patent application Ser. No. 12/189,424, with the iron nitrate solutions being formed as described in this disclosure. This catalyst is made using elemental iron and optionally copper as starting materials. The disclosures of U.S. Pat. No. 5,504,118 and U.S. patent application Ser. No. 12/189,424 are hereby incorporated herein in their entirety for all purposes not inconsistent with this disclosure.

The first step in the preparation of the raw catalyst is dissolution of the metals in nitric acid to form a mixture of ferrous nitrate, ferric nitrate and optionally cupric or at least one other metal nitrate in appropriate proportions. In embodiments, Fe(II)/Fe(III) nitrate solution having a desired ratio of ferrous to ferric iron in the acid solution is formed as described in Section II hereinabove. Specifically, a stable ferrous nitrate solution is formed, a ferric nitrate solution is formed, and appropriate amounts of the stable ferrous nitrate and ferric nitrate solutions are combined to yield a stable ferric/ferrous nitrate solution having the desired ratio of ferric to ferrous iron.

In embodiments, the next step in the FT catalyst formation is precipitation of a catalyst precursor from the nitrate solution using a precipitating agent (base.) In embodiments, the precipitating agent (base) is selected from the group consisting of NH4OH, (NH4)2CO3, NH4HCO3, NaOH, Na2CO3, NaHCO3, KOH, K2CO3, KHCO3, and combinations thereof. In embodiments, the precipitating agent comprises sodium carbonate. In embodiments, the base comprises ammonium hydroxide.

Precipitation agent (e.g. base) can be added to nitrate solution, or nitrate solution added to base. In embodiments, precipitation agent (e.g. base) is added to hot nitrate solution at ambient temperature. The amount of precipitation agent (e.g. base) can be such that the pH of the solution reaches a value in the range of from about 7.0 to about 7.5, e.g. about 7.4. At this point, metals precipitate out as oxides, hydroxides, carbonates, or a combination thereof. The mixture can then be cooled (e.g., to about 80° F.) and/or the final pH adjusted. The final pH can be adjusted to a pH in the range of from about 7.0 to about 7.5, e.g. a pH of about 7.2.

Following precipitation, the catalyst precursor can be washed using high quality water which is preferably free of chlorine. The washing can be performed according to any methods known in the art. In embodiments, the slurry is introduced, e.g. pumped, from the precipitation vessel into a holding tank. The holding tank can be located upstream of a filtration apparatus, e.g. a vacuum drum filter. The catalyst precursor may be allowed to settle in the holding tank and a clear layer of concentrated solution may form above the solids. This layer may be drawn off before the slurry is washed and filtered. A vacuum drum filter fitted with water spray bars may be used for washing the catalyst precursor and concentrating the slurry. The electrical conductivity of the filtrate can be monitored to ensure complete washing of the catalyst precursor has been effected. For example, the catalyst precursor can be washed until the electrical conductivity of the filtrate is about 40, about 30, or about 20 percent or less of the original electrical conductivity.

Following washing, the precipitate (or washed precipitate) can be alkalized by any means known in the art. For example, the addition of potassium carbonate can be used to alkalize the precipitate or washed precipitate. In embodiments, alkalization is performed prior to spray drying in order to adjust the Fe:K ratio to a desired value. In embodiments, alkalization is performed prior to spray drying in order to provide a desired Fe:K ratio. For example, in embodiments, following washing of catalyst precursor, potassium carbonate is added in an amount appropriate for the quantity of iron contained in the batch. Potassium is a promoter for chain growth and may also maintain the catalyst in iron carbide form. Adding more than appropriate amount of potassium may cause formation of more oxygenated products which may oxidize the catalyst, and is generally avoided. In embodiments, potassium carbonate is added to the slurry after washing is completed and prior to spray drying. Potassium carbonate can be dissolved in a small amount of water and this solution mixed thoroughly with the catalyst precursor slurry to uniformly distribute the potassium. In embodiments, the weight percent of solid catalyst material in the slurry at this point is in the range of from about 8 to about 12.

In embodiments, as described in U.S. patent application Ser. No. 12/198,459 filed Aug. 26, 2008 and entitled, “Strengthened Iron Catalyst for Slurry Reactors,” the iron FT catalyst further comprises a structural support such as a binder incorporated after precipitation of the catalyst precursor or a support material coprecipitated with iron. The support material may serve to increase the structural integrity of the catalyst. In embodiments, the iron catalyst of the present disclosure comprises coprecipitated material selected from iron, silica, magnesium, copper, aluminum, and combinations thereof. Alternatively, or additionally, potassium silicate binder, colloidal silica, and/or tetraethyl ortho silicate (TEOS) can be added to a precipitated catalyst to increase the strength thereof.

In embodiments, the structural promoter is incorporated into the iron catalyst by coprecipitation. The structural promoter and its incorporation can be as described in U.S. patent application Ser. No. 12/207,859, which is hereby incorporated herein. The iron catalyst precursor can be prepared by co-precipitation of copper, silicon, magnesium, and aluminum with iron to provide an FT catalyst that exhibits high activity, selectivity, and stability.

In embodiments, the structural promoter is added to a conventional precipitated catalyst subsequent precipitation of the catalyst precursor comprising iron hydroxides, iron oxides and/or iron carbonates. In embodiments, structural promoter is coprecipitated with the catalyst material, and additional structural promoter (e.g. binder) is added following the precipitation of the catalyst material.

In embodiments structural promoter comprising silicon is added to a catalyst precipitate, the precipitate comprising iron phases. The iron phases can include iron hydroxides, iron carbonates, iron oxides, and combinations thereof. The structural promoter can comprise potassium silicate aqueous solution, which will be referred to herein as liquid potassium silicate. In embodiments, the liquid structural promoter comprises tetraethyl ortho silicate, TEOS, or potassium silicate and is added such that the catalyst has a silica content of from about 1 wt. % to about 2.2 wt. %.

As mentioned above, in embodiments, various amounts of liquid potassium silicate (K2SiO3) are added to a raw precipitated catalyst. In embodiments, precipitated iron catalyst is impregnated by mixing thoroughly with various amounts of aqueous potassium silicate. In embodiments, the precipitate is heated to 125° C. at the rate of 2° C./min, and held at this temperature for 12 h, and then ramped to 350° C. at the rate of 1°/min, and calcined at this temperature for 16 h prior to impregnation with aqueous potassium silicate solution. In other embodiments, liquid potassium silicate is added to iron precipitate prior to spray drying of the impregnated precipitate. The iron catalyst can comprise SiO2 concentrations in the range of from about 1.0 weight percent to about 2.2 weight percent. The potassium silicate solution can comprise SiO2/K2O in a desired ratio for the production of catalyst having the desired composition.

Preparation of precipitated catalyst can comprise: Forming a stable solution of ferrous nitrate, forming a solution of ferric nitrate, and combining desired amounts of stabilized ferrous nitrate solution and ferric nitrate solution such that a stable Fe(II)/Fe(III) nitrate solution is formed having a desired ratio of ferrous to ferric iron.

As described in Section II hereinabove, formation of stable ferrous nitrate solution can comprise dissolving iron in nitric acid having a weight percent and maintaining the solution at a first temperature for a period of time. In embodiments, the first temperature is a temperature of from about 25° C. to about 35° C. In embodiments, the first temperature is a temperature in the range of from about 30° C. to about 35° C. In embodiments, the period of time is greater than about 30 minutes. In embodiments, the period of time is greater than about 40 minutes. In embodiments, the period of time is greater than about 45 minutes. In embodiments, the nitric acid used to dissolve the iron for preparation of the stable ferrous nitrate solution is about 5 to 10 weight percent nitric acid, about 6-9 weight percent nitric acid, or about 6 weight percent nitric acid.

How KEYWORD MONITOR works... a FREEservice from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Stable ferrous-ferric nitrate solutions for fischer-tropsch catalyst preparation or other areas of interest.###

Data source: patent applications published in the public domain by the United States Patent and Trademark Office (USPTO). Information published here is for research/educational purposes only. FreshPatents is not affiliated with the USPTO, assignee companies, inventors, law firms or other assignees. Patent applications, documents and images may contain trademarks of the respective companies/authors. FreshPatents is not responsible for the accuracy, validity or otherwise contents of these public document patent application filings. When possible a complete PDF is provided, however, in some cases the presented document/images is an abstract or sampling of the full patent application for display purposes. FreshPatents.com Terms/Support -g2-0.158